Low viscosity, highly concentrated pigment dispersions

Description

[0001] The present invention relates to pigment disper­sions containing a viscosity-reducing additive. By lowering the viscosity of the dispersions, still more pigment may be added to the dispersions, resulting in a very highly concentrated dispersion which can be satisfactorily handled and dispersed.

[0002] Pigments sold to ink manufacturers are usually in two forms: (1) dry powders and (2) concentrated disper­sions. Pigments sold in the second form are offered at as high a concentration as the ink manufacturer can use, in order to provide the following advantages to the ink manufacturer:

(A) a more concentrated pigment dispersion allows the inkmaker greater formulating latitude (e.g. to increase performance or lower costs) because less dispersion must be added to maintain any particular pigment level in the ink; and

(B) the greater formulating latitude permits the inkmaker to produce a wider variety of inks (e.g. the same dispersion could go into heat-­set, quick-set, and news ink);

(C) the more concentrated pigment dispersion permits a lower inventory volume and less raw material testing by the inkmaker.

[0003] The upper limits of pigment concentration are determined by physical handleability. As the pigment concentration in the dispersion increases linearly, the viscosity of the dispersion increases exponentially. If the dispersion is too high in viscosity, the inkmaker can no longer satisfactorily disperse the concentrated pigment in the ink manufacturing process. Furthermore, as the pigment concentration increases, the ink manufacturer experiences increasing frictional heat buildup during the dispersion process. This heat buildup will degrade certain pigments. In addition, as the inkmaker's dispersion difficulties increase, so does the amount of labor-intensive handling required to achieve successful dispersion.

[0004] Most pigment dispersion manufacturers operate near an upper limit of pigment concentration, in order to provide inkmakers with the several advantages described above, without creating the problems resulting from too high a pigment concentration. The product and method of the present invention enable the manufacturer of a pigment dispersion to significantly decrease the viscosity of a pigment dispersion by adding a relatively small amount of a viscosity-reducing agent. The lower viscosity allows the pigment dispersion manufacturer, in turn, to increase the pigment concentration back to the point at which the resulting maximum viscosity is reached. Thus the pigment dispersion manufacturer may now produce a dispersion which has a viscosity at the maximum amount and pigment concen­tration significantly above the concentration attainable without use of the additive.

[0005] The object of the invention was to provide pig­ment dispersions which can readily be processed to printing inks even when the pigment content is fairly high.

[0006] The invention relates to a pigment dispersion comprising

(a) at least 20 percent, by weight of dispersion pigment; and

(b) at least 35 percent, by weight of dispersion, carrier; and

at least 1.0 percent, by weight of pigment, of an oil-­soluble additive which is a reaction product of an oil-soluble, long chain aliphatic amine having a molecular weight between 80 and 340 and an organic acid having at least two carboxylic acid groups and a molecular weight between 150 and 250.

[0007] The novel dispersions with the additive have, with a high pigment content, virtually the same viscosity as prior art dispersions containing no additive.

[0008] Additives (c) according to the invention are not suggested by PCT Application WO 84/02142, which dis­closes the use of a water-soluble buffer for use in water-­based lithographic fountain solutions in which the buffer is a salt of a polycarboxylic acid and an organic amine. The use of an oil-soluble additive based on a long-chain aliphatic amine and an at least dibasic acid in an oil-­based flush is not suggested by this literature.

[0009] What is essential to the invention is component (c) - the viscosity-reducing additive-, which the dis­persion contains in an amount of at least 1.0, and prefer­ably from 1 t0 10, percent (based on the weight of pigment in the dispersion).

[0010] The viscosity-reducing additive used in present invention is a reaction product. The most preferred additive is a salt. In general, the salt can be made by:

(1) dissolving the amine in an aliphatic solvent, in order to form an amine solution; and

(2) heating the amine solution to approximately 90°C, accompanied by mild agitation; and

(3) discontinuing heating and simultaneously adding the acid, followed by mixing the acid with the amine solution for above 15 minutes while the amine solution is cooling, followed by allowing the resulting mixture to cool to room temperature.

[0011] Preferred additives are those obtained by reaction of 1 mole of amine with 1 mole of acid. In addition, the preferred molar ratio of aliphatic solvent to amine is 6:1. Several preferred solvents include, among others: methanol, isopropanol, toluene, aliphatic hydrocarbons including petroleum distillates having a boiling range of 200°C to 375°C (e.g. Magiesol 47). Other solvents believed operable include: ethanol, n-propanol, butanol, xylene, mineral spirits, VMP naptha, Solvesso No. 100, acyclic ketones and ethers such as methyl isobutyl ketone, and ethylene glycol monomethyl ether.

[0012] The amine used to make the additive is an oil-­soluble, long-chain aliphatic amine having a molecular weight between 80 and 340. The amine must be oil-soluble in order to form an oil-soluble salt with a non-oil-soluble organic acid. By "long-chain" it is meant that the longest carbon chain ranges from C6 to C20. Several preferred amines include, among others: octylamine, n-dodecylamine, tetradecylamine, n-octadecylamine, cocoamine, tallowamine, hydrogenated tallow amine and oleylamine.

[0013] The acid used to make the additive is an organic acid having at least two carboxylic acid groups and a mole­cular weight between 150 and 250. Preferred polybasic acids include succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, and citric acid. Adipic acid is particularly preferred.

[0014] The additive (c) is incorporated into the pigment dispersion in an amount of 1 to 10 percent by weight (based on weight of pigment). It is preferable to incorporate be­tween 1 percent and 8 percent (based on weight of pigment) additive into the dispersion.

[0015] The additive may be incorporated in the disper­sion either during the production of the dispersion or after the dispersion has been produced. Preferably the additive is incorporated into the flush during either the break stage (when phase transfer is occurring) or afterwards in the dilution or thinning stage. The additive is incorporated into the dispersion by simply mixing the additive thereinto.

[0016] This invention may be employed in conjunction with the production of many different pigments. Examples of pigments for which this invention is applicable iden­tified by the Color Index or C.I. names are as follows:

[0017] Pigment Red 1, Pigment Red 3, C.I. No. 12,120; Pigment Red 4, C.I. No. 12,085; Pigment Red 48:1, C.I. No. 15,865:1; Pigment Red 48:2, C.I. No. 15,865:2; Pigment Red 48:3, C.I. No. 15,865:3; Pigment Red 48:4, C.I. No. 15,865:4; Pigment Red 49:1, C.I. No. 15,630:1; Pigment Red 49:2, C.I. No. 15,630:2; Pigment Red 53:1, C.I. No. 15,585:1; Pigment Red, C.I. No. 15,860; Pigment Red 57, C.I. No. 15,850; Pigment Red 81, C.I. No. 45,160:1; Pigment Red 190, C.I. No.71,140; Pigment Orange 13, C.I. No. 21,110; Pigment Orange 19, C.I. No. 15,990; Pigment Orange 46, C.I. No 15,602; Yellow 12, C.I. No. 21,090; Pigment Yellow 13, C.I. No. 21,100; Pigment Yellow 14, C.I. No. 21,095; Pigment Yellow 17, C.I. No. 21,105; Pigment Yellow 27, Pigment Yellow 83, C.I. No. 21,108; Pigment Green 7, C.I. No. 74,260; Pigment Green 36, C.I. No. 74,265; Pigment Blue 6, Pigment Blue 15:3, C.I. No. 74,160; Pigment Blue 61, C.I. No. 42,765:1.

[0018] Of these pigments, Pigment Red 57 and Diarylide Yellow pigments (Pigment Yellow 12, 13 and 83) are preferred.

[0019] The term "carriers", as used herein refers to any of the hydrophobic organic vehicles that are commonly used in printing ink and coating compositions which may be employed in the method and composition of this invention. Such vehicles are represented by drying, semi-drying, and non-drying oils, litho varnishes, mineral oil, rosins, dimerized rosins, esters of dimerized rosins, aliphatic and aromatic hydrocarbon resins, alkylaromatic resins, maleic and fumeric-modified rosin, phenolic resin, phenolic- modified rosin esters, alkyd resins, urethane-modified alkyds, polyolefins, polyindenes, coumarone/indene resins, phthalate esters, castor oil, fish oil, linseed oil, gloss varnishes, and various heat-set, quick-set, and steam-set vehicle systems.

[0020] The vehicle may be a solution of a resin or mixture of resins and other additives in a solvent.

[0021] Typical resins which can be advantageously employed in such solutions are illustrated in the following table:

TABLE 1

No.	Resin Type	Trade Name of Resin
1.	Isophthalic Alkyd based on Linseed Oil	AVO-791
2.	Polyamide Alkyd	Nylin 5
3.	Phenolic Modified Rosin Ester of Abietic Acid	Beckacite® 24-102
4.	Maleic Modified Rosin Ester of Abietic Acid	Filtrez 3790
5.	Pentaerythritol Ester of Dimeric Resin Acids	Pentalyn K
6.	Aliphatic Hydrocarbon	Piccovan® AB165
7.	Aromatic Hydrocarbon	LX®-685-135 200
8.	Modified Hydrocarbon	Nevroz® 1420
9.	Aromatic-Aliphatic Hydrocarbon	Petrorez 200

[0022] As solvent in the resin-solvent type vehicle there may be employed aliphatic hydrocarbons, including petroleum distillates having a boiling range of 200°C. to 375°C., petroleum solvents such as mineral spirits and VMP nahtha, petroleum aromatic solvents, such as Solvesso No. 100, aromatic solvents having a boiling range 150° to 185°F and a KB value of 91, aromatic solvents having a KB value of 92 to 100 such as xylene, and cyclic alcohols, ketones, and ethers, such as butanol, methyl isobutyl ketone, and ethylene glycol monomethyl ether. The solvent mixtures will vary with the resins used and may be adjusted accordingly, but must be capable of dissolving the resin completely.

[0023] The dispersions may contain pigments in concen­trations ranging from 20 percent to 65 percent (by weight of dispersion). Preferably, however, the pigment concentration within the dispersion is from 30 percent to 55 percent (by weight of dispersion). Mixtures of pigments may be used. As is described in Example 2, below, it is preferable to use the additive to reduce viscosity so that a still more concentrated pigment dispersion can be made, this "more concentrated" dispersion having a viscosity near the maximum viscosity which an inkmaker can utilize. To this end, it is preferable to make a dispersion having a viscosity at 40°C of between 1000 and 6000, especially of approximately 3000 poise at 0.5 sec⁻¹ and a yield value at 0.05sec⁻¹ of approximately between 200 and 1000 dynes/cm², especially of 300 dynes/cm². Preferably the dispersions having this viscosity will also have a pigment concentration between 30 percent and 55 percent pigment (by weight of dispersion).

Example 1

a) Additive Preparation

[0024] A 281.25 gram aliquot of Magiesol 47, an aliphatic hydrocarbon petroleum distillate, was combined (in a vessel) with 112.5 grams (0.40 moles) of Armeen® 18D, an alkylamine having a C-18 average chain length. The mixture was heated until it reached 90°C, under mild agitation. Then 56.25 grams (0.39 moles) of adipic acid were added to the vessel, and the mixture was mixed for 15 minutes with the heat turned off. After mixing, the mixture was allowed to cool slowly to room temperature. The product was found to contain 37.5% active salt, based on the weight of the mixture.

b) Incorporation of the Additive into a Pigment Dispersion (Flush 1)

[0025] An experimental flush (i.e. a color base in paste form) was prepared as follows. A presscake contained 500 parts (23.6 percent by weight of presscake) of C.I. Pigment Red 57:1; C.I. No. 15,850:1. The presscake was divided into four fractions of equal weight. Two of these fractions were added to a sigma blade mixer known as a flusher. The flusher was started. Steam was applied to the jacket until the temperature reached 65°C. Then the following material was added:

(a) 52 parts of a linseed oil alkyd; and

(b) 176 parts of a solution of 72 percent Filtrez 3790/28 percent Magiesol 47; and

(c) 122 parts of a solution of 60 percent Petrorez 140/40 percent Magiesol 47;

after which a first break occurred and the flusher was stopped. The clear aqueous phase was poured off.

[0026] Then the third fraction (125 parts of pigment in the form of presscake) was added to the flusher. The flusher was started and again heated to 65°C. 63 Parts of a solution of 60 percent Petrorez 140/40 percent Magiesol 47 were added, the next break occurred and the flusher was stopped. Again, the clear aqueous phase was decanted.

[0027] Then the fourth fraction (125 parts of pigment in the form of pressecake)was added to the flusher. The flusher was started again and heated to 65°C. 79 parts of 60 percent Petrorez 140/40 percent Magiesol 47 were added, the last break occurred and the flusher was stopped. The clear aqueous phase was then decanted.

[0028] After the last break was poured, 77 parts of 60 percent Pentalyn® K/40 percent Magie 535 were added, along with 26 parts of 60 percent Petrorez 140/40 percent Magiesol 47. The flusher was started, sealed and vacuum applied. The flusher was run until the batch temperature reached 110°C. At this point the cold water was turned on the jacket, and 93 parts of the additive (prepared under a)) along with 147 parts of a solution of 60 percent Petrorez 140/40 percent Magiesol 47 and 25 parts of water were added. The flusher was stopped while still under vacuum. The flusher was occasionally started and quickly stopped over a period of fifteen minutes to allow for rapid cooling. After this point, the temperature of the batch was 70°C and the cold water on the jacket was turned off.

[0029] The flusher was started, maintaining vacuum and the remaining flush thinning vehicle composed of:

(a) 47 parts of a solution of 72 percent Filtrez 3790/28 percentage Magiesol 47; and

(b) 125 parts of a solution of 60 percent Petrorez 140/40 percent Magiesol 47; and

(c) 6 parts of Magiesol 47

were added as fast as possible. The vacuum was then shut off and the finished product removed from the flusher. The resulting experimental flush contained 33 percent pigment based on the weight of the flush.

[0030] Then a corresponding control flush was prepared as described in Example 3.

[0031] The viscosity of the control flush was then qualitatively compared with the viscosity of the experi­mental flush. The qualitative comparison was carried out by manually "feeling" the flush. The test resulted in a "softness" rating. The softer the flush was, the lower the viscosity of the flush. Relative to the control flush, the experimental flush had a rating of very soft. Since both the experimental flush and the control flush contained approximately the same percent pigment, the presence of the additive had a significant effect on the viscosity of the flush.

Example 2

a) Additive Preparation

[0032] 2000 grams of 60 percent Petrorez 140/40 percent Magiesol 47 were added to a vessel along with 168 grams of Magiesol 47. This was heated to 90°C. Then 168 grams (0.60 moles) of Armeen® 18D (essentially C₁₈-alkylamine) were added to the beaker, after which the resulting mixture was stirred for 10 minutes to dissolve the amine. 84 grams (0.57 moles) of adipic acid were then added to the beaker, following which the mixture was stirred for 30 minutes. The mixture was then allowed to slowly cool to room temperature. The resulting mixture was found to contain 10.4 percent active salt (based on weight of the mixture) of Armeen® 18D and adipic acid.

b) Incorporation of the Additive into a Pigment Dispersion (Flush 2)

[0033] An experimental flush was prepared as follows. A presscake contained 500 parts (23.8 percent by weight of presscake) of a Lithol Rubine pigment. The presscake was divided into 4 fractions of equal weight. Two of these fractions were added to a sigma blade mixer known as a flusher. The flusher was started. Steam was applied to the jacket until the temperature reached 65°C. Then the following materials was added:

(a) 52 parts of a linseed oil alkyd; and

(b) 177 parts of the additive made above;

after which the first break occurred and the flusher was stopped. The clear aqueous phase was poured off.

[0034] . 125 additional parts of pigment (third fraction) in the form of the presscake and 73 parts of additive from a) were added to the flusher. The flusher was started and again heated to 65°C. A second break then occurred and the flusher was stopped. Again, the clear liquid phase was decanted.

[0035] Then the fourth fraction (125 parts of pigment in the form of the presscake) and 57 additional parts of the additive from a) were added to the flusher. The flusher was started and again heated to 65°C. 27 Additional parts of the additive were then put into the flusher. The next break occurred and the flusher was stopped. Again, the clear aqueous phase was decanted.

[0036] After the last break was poured, 26 parts of 60 percent Petrorez 140/40 percent Magiesol 47 were added to the flusher. The flusher was started, seated and vacuum applied. The flusher was run until the batch temperature 110°C. At this point the cold water was turned on the jacket, and

(a) 67 parts of the Petrorez 140/Magiesol 47; and

(b) 5 parts of a mixture of 25 percent butyl hydroxy toluene/75 percent Magiesol 47; and

(c) 25 parts of water

were added, and the flusher was stopped while still under vacuum. The flusher was occasionally started and quickly stopped over a period of 15 minutes to allow for rapid cooling. After this point, the temperature of the batch was 70°C and the cold water on the jacket was turned off. The flusher was started, maintaining vacuum, and the remaining flush thinning vehicle composed of:

(a) 34 parts Magiesol 47; and

(b) 115 parts of 60 percent Petrorez 140/40 percent Magiesol 47

was added as fast as possible. The vacuum was then shut off and the finished product removed from the flusher. The resulting flush (flush 2) contained 45.8 percent pigment, based on the weight of the flush.

[0037] Since flush 2 contained significantly more pig­ment than the control (flush 3) (45.8 percent vs. 34 percent for the control), normally the viscosity of flush 2 would be significantly higher than flush 3. However, when the viscosity of both the flush 3 and flush 2 was tested manually (as described in Example 1), it was found that flush 2 was slightly less viscous than flush 3 (the compara­tive rating was slightly softer). The lower viscosity of flush 2 was attributed to the presence of the additive.

[0038] This example illustrates how the composition and process of the present invention enable one to significantly increase the pigment concentration in the flush without increasing the viscosity of the flush. Thus, by using the composition and process of the present invention, one may provide the inkmaker with a flush which offers advantages due to its higher pigment concentration without the dis­advantage of higher viscosity.

Example 3

Preparation of a Control Flush 3)

[0039] A presscake contained 500 parts (23.6 percent by weight of presscake) of a Lithol Rubine pigment. The presscake was divided into four fractions of equal weight. Two of these fractions were added to a sigma blade mixer known as a flusher. The flusher was started. Steam was applied to the jacket until the temperature reached 65°C. Then the following material was added: of these fractions were added:

(a) 52 parts of a linseed oil alkyd; and

(b) 176 parts of 72 percent Filtrez 3790/28 percent Magiesol 47; and

(c) 94 parts of 60 percent Petrorez 140/40 percent Magiesol 47;

after which a first break occurred and the flusher was stopped. The clear aqueous phase was poured off.

[0040] 125 Additional parts of pigment in the form of one additional fraction of presscake were added to the flusher. The flusher was started and again heated to 65°C. 87 Parts of 60 percent Petrorez 140/40 percent Magiesol 47 were added, the next break occurred and the flusher was stopped. Again, the clear aqueous phase was decanted. Then a final 125 parts of pigment, in the form of the last remaining fraction of presscake, were added to the flusher. The flusher was started and again heated to 65°C. Then 21 parts 60 percent Petrorez 140/40 percent Magiesol 47 were added to the flusher, along with 18.3 parts of 77 percent Pentalyn® K/40 percent Magie 535, a third and final break occurred, and the flusher was stopped. Again, the clear aqueous phase was decanted.

[0041] After the last break occurred, 78 parts of 60 percent Petrorez 140/40 percent Magiesol 47 were added to the flusher. The flusher was started, sealed and vacuum applied.

[0042] The flusher was run until the batch temperature reached 110°C. At this point, the cold water was turned on the jacket, and

(a) 208 parts of 60 percent Petrorez 140/40 percent Magiesol 47; and

(b) 30 parts Magiesol 47; and

(c) 5 parts of 25 percent butyl hydroxyl toluene 75 percent Magiesol 47; and

(d) 25 grams of water

were added, and the flusher was stopped while still under vacuum. The flusher was occasionally started and quickly stopped over a period of fifteen minutes to allow for rapid cooling. After this point, the temperature of the batch was 70°C and the cold water on the jacket was turned off. The flusher was started, maintaining vacuum, and the remaining flush thinning vehicle composed of:

(a) 125 parts of 60 percent Petrorez 140/40 percent Magiesol 47; and

(b) 31 parts Magiesol 47; and

(c) 47 parts of 72 percent Filtrez 3790/28 percent Magiesol 47

were added as fast as possible. The vacuum was then shut off and the finished product removed from the flusher. The resulting flush (flush 3) contained 34 percent pigment, based on the weight of the flush.

Claims

1. A pigment dispersion comprising:

(a) at least 20 percent, by weight of dispersion, pigment; and

(b) at least 35 percent, by weight of dispersion, carrier; and

(c) at least 1.0 percent by weight of pigment, of an oil-soluble additive which is a reaction product of an oil-soluble, long chain aliphatic amine having a molecular weight between 80 and 340 and an organic acid having at least two carboxylic acid groups and a molecular weight between 150 and 250.

2. A pigment dispersion as set forth in claim 1 wherein the pigment (a) is an organic pigment.

3. The pigment dispersion as set forth in claim 1 or 2 wherein the additive (c) is a salt of one mole of the aliphatic amine and of one mole of the organic acid.

4. The pigment dispersion as set forth in claim 1, 2 or 3 wherein the acid is adipic acid.

5. The pigment dispersion as set forth in claim 1, 2, 3 or 4 wherein the amine is an alkylamine having a C-18 average chain length.

6. The pigment dispersion as set forth in claim 1, 2, 3, 4 or 5 wherein the dispersion comprises 1 to 10 percent, by weight of pigment, additive (c).

7. The pigment dispersion as set forth in claims 1 to 6 wherein the dispersion comprises 20 to 60 percent, based on weight of dispersion, of pigment (a).

8. The pigment dispersion as set forth in claims 1 to 6 wherein the dispersion comprises 30 to 55 percent, based on weight of dispersion, of pigment.

9. The pigment dispersion as set forth in claims 1 to 8 wherein the dispersion has a viscosity at 40°C of be­tween 1,000 and 6,000 poise at 0.5 sec⁻¹ and a yield value at 0.05 sec⁻¹ of between 200 and 1000 dynes/cm².

10. A pigment dispersion as set forth in claims 1 to 9 wherein the pigment (a) is C.I. Pigment Red 57:1, C.I. No. 15,850:1.

11. A pigment dispersion as set forth in claims 1 to 9 wherein the pigment (a) is Diarylide Yellow pigment.

12. The pigment dispersion as set forth in claims 1 to 11 wherein the dispersion comprises between 1 percent and 8 percent, by weight of pigment, additive (c).